Fred's 1983 KP60 Toyota Starlet, take 2!

Post by **Fred** » Mon Jul 18, 2016 1:37 pm

Modified slightly, some lines split, some new lines, some reordered...

Fred wrote:

DONE! Drive it out into the open

DONE! Refill it with straight water

DONE! Bring it up to temperature, perhaps with a drive

DONE! Dump the water, flushing as much as I can through with the hose

DONE! Fill with concentrated oxalic acid - no fear of water pump issues, it's coming out anyway. The rest could do with a derust :-p

DONE! Take it for a drive to get full cooling system coverage at a nice high temperature

DONE! Come home and dump the acid out

SKIPPED Flush with fresh water a few times until satisfied

DONE! Fill with strongish solution of sodium carbonate (not bicarbonate like last time's minor fail/explosion)

DONE! Take it for another drive to ensure that circulates through the entire system too

DONE! Bring it home and dump out the carbonate solution

DONE! Flush with water until satisfied

DONE! Oil change, fill it with cheap 15w40 and maybe a new filter if it's lucky :-p

DONE! Blow cooling system parts/engine dry with compressed air

DONE! Back into the garage she goes

DONE! Remove hoses from water pump and radiator

DONE! Remove radiator from car and flush with water

DONE! Pull the water pump off the engine

DONE! Pull the alternator off the engine

DONE! Pull the trigger wheel off the engine (blocks access to large bolt)

DONE! Pull the pulley off the engine (blocks access to small loose bolt)

DONE! Degrease the front cover and clean under the water pump etc

DONE! Pull the loose bolt out and clean the hole

DONE! Put away all tools, neatly arrange parts so they're not lost

DONE! Hose down driveway extensively half a dozen times...

Measure the hole depth, find a suitable replacement, torque up the new bolt with locktite

Get the alternator fixed up and in good shape - as quickly as possible, reinstall as is if no luck

Reverse of the above, but with new water pump and refill with nice green coolant for the first time in years, LOL.
That's basically a whole day

That was indeed a whole day. Caravan now back in the parking spot blocking it in again.

So left to do are:

Sort out the bracket fastener situation
Tweak the bracket to give more clearance for drain bung and water pump bolt
Fix one radiator mount bracket
Derust and paint a few items
Pull the radiator support out of the car, clean up, paint, reinstall
Scrub rusty water stains from fan shroud
Scuff up the pump mounting face until bright steel
Clean various fasteners that are greasy and/or rusty
Install the new water pump with a small amount of well placed silicone
Get the alternator fixed ASAP
Reinstall pulley, trigger wheel, bracket, sensor, bolts
Reinstall alternator and belt, tension belt correctly
Refill with water for the first time, bring up to temperature, check for pressure and leaks
Drain water, refill with glycol coolant at 35% and water 65%

On the brighter side, I put about 20km on it today driving up and down the hill with various radiator contents. Fun little car!

On the weirder side, it was slower post oil change! Why?

1) Higher oil level
2) Old oil was broken down and thin

IE, higher net friction post change.

Tweets to come. Yet to upload. Shower time!

ToxicGumbo · Post by **ToxicGumbo** » Mon Jul 18, 2016 9:40 pm

Since Fred's asleep in NZ and dreaming of boost, here are the tweets with images and captions:

The mighty KP60 is out in the world warming up (my toes)

Out with the old and small. #KP60 #4K oil filter

In with the new and bigger. #KP60 #4K oil filter

Found some large pieces of silicone in the radiator. Amateur professional mechanics failing at life. #KP60

Driver visible overflow tube with sodium carbonate in the cooling system. #KP60

]

You wouldn't believe that this was old and rusty this morning. #KP60 radiator cap post acid bath!

Another angle of acid-clean #KP60 radiator cap

#KP60 overflow bottle also got the acid treatment.

That explains the slightly loose/rattly radiator mounting in the #KP60

Back face of the old #4K water pump and the source of the silicone pieces I found floating around in the #KP60

Another shot of the back of the #4K #KP60 water pump. Note filth in background. See later tweet for clean version

Neglected and abused #4K in my #KP60

It's OK, I'm taking care of you now. <3 Note filthy housing on left

Old genuine #Toyota #4K water pump showing clear evidence of massive leakage

#KP60

Old genuine #Toyota #4K water pump showing clear evidence of massive leakage

#KP60

Ha! Some of it is alloy, and other bits steel. It was all just black/brown before :-p #4K #KP60 #Degreased

This #4K pulley has been machined... On the car... By a bolt...

#KP60 #roadtrip #mission #carnage

Bolt come cutter, take one. This bolt machined my #4K pulley... On the car...

#KP60 #roadtrip #mission #carnage

Bolt come cutter, take two. This bolt machined my #4K pulley... On the car...

#KP60 #roadtrip #mission #carnage

Alternator is out and on the ground! #4K #KP60

#4K tstat is 28mm, as is the radiator top hose barb. 34 for the lower and pump. #KP60

Inside a neglected cooling system hose. Yes, that's black rubber. You just can't tell. Yet. :-p #4K #KP60

Post by **Fred** » Mon Jul 18, 2016 11:41 pm

ToxicGumbo wrote:Since Fred's asleep in NZ and dreaming of boost, here are the tweets with images and captions

Wrong thread for dreaming of boost. I tend to dream of rev limiters and ITB noise in this thread :-D

Thanks Jeff! I pulled the MG links/pics out. I like your image links to tweet style. Cheers!

Post by **Fred** » Tue Jul 19, 2016 6:02 am

Today has been contemplative, however I did a bit of work on the alternator and pulled a bracket off to clean it. Alternator is in pieces now and ready for desoldering and checking. Tweets/pics, semi-toxic style:

Post by **Fred** » Tue Jul 19, 2016 8:16 am

Went down to play around a little and ended up making myself some room to work:

The very convenient unboltable radiator support panel had some surface rust in places, and some ugly rust killer slapped over it in a haphazard way. So I figured I'd take it out, gain the space to work on the engine, and tidy it up before reinstallation. Then when I got it off I was reminded of some badly done minor chassis rail rust repairs that I wanted to redo properly. And the bumper brakets are brown with surface rust, too. And I have those H4 headlights to swap in. So it looks like the front end will get a minor make over, likely just black zinc primer for now, before the front goes back together.

Once that's all done, engine running, front end in one piece and looking clean, neat, and tidy underneath, then I'll pull the bonnet off and give that some love as it's had the same ugly haphazard rust killer treatment on the bracing underneath (the skin is 100% good). I don't like having ugly stuff like that plainly visible when taking it for an inspection, or even when looking at it myself. So I'll try to resolve these easy flaws as a priority.

A thought just occurred to me: I'll be cutting a perfectly good, much larger, trans tunnel out of the caravan at some point. Perhaps some or all of it can end up grafted into the KP to help the J160 fit in there? Could be a winner! I love reuse :-D

After I had the front all apart (around 10 mins, tops!) I had a look at the VR sensor bracket and recalled some clearance issues. So I marked it up for cutting and did the one quiet piece of work I could with a file. The balance tomorrow with an angle grinder. You can clearly see the grease/rubber/iron dust on the thing, thrown by the pulley and bolt rubbing on it :-D

Post by **Fred** » Wed Jul 20, 2016 12:27 pm

Post by **Fred** » Wed Jul 20, 2016 9:29 pm

https://www.amazon.com/gp/aw/d/B008L2HK7U

As dodgy as those are, they'll do nicely for bolting my modified 16" FC3S front runners to the KP for drag strip LOLs :-)

ToxicGumbo · Post by **ToxicGumbo** » Wed Jul 20, 2016 9:46 pm

Voila!

What upto 1600km of vibrating against the outer most thread of the hole it should've been in does "View image" #KP60

Brass #4K block drain valve plug cleaned and ready for reinstallation. #KP60

All 6 diodes show ~0.6V fwd drop. 1 is lower at about 0.53V. None of the 3 windings are open circuit. #KP60 #KPFAIL

Disk-Lock washer, alternative to Nordlock. #KP60 fix

From left to right, the old, the new, the measuring device. Old had about 2 threads engagement... #KP60 fix

A handful of 304 #StainlessSteel button headed M6 12mm cap screws for prettying up the #KP60 engine bay. Kiwi owned!

A treat for me and the #KP, some quality black zinc primer. #KP60 tidy up

Water pump mounting face on the #4K block cleaned up with wet'n'dry paper

#KP60 fixing

Wire wheeled around the edge and scuffed up with 100 grit ready for RTV and water pump. #KP60 fixing

Found where that heat shield came from! #KP60 engine mount..

Air cleaner lid treated with rust killer in preparation for zinc primer. #KP60 tidy up

Bracket slimmed down and test fitted, but needs a little more clearance for serviceability. #KP60 improvements

VR sensor bracket fits perfectly now, cleaned, and in position ready for a pulley

#KP60 fixing

New bolt and lock washer have sufficient clearance to not cause anymore dramas. #KP60 fixing

Chasing the water pump bolt holes with a tap before installation. #KP60 fixing

New water pump is installed on the mighty #KP60

A bit of black zinc on the VR tone wheel standoffs. #KP60 improvements

VR wheel cap screws greased for a longer, less ugly, and rust free life. #KP60 improvements

Air filter cover looks tidy, but doesn't match anything anymore

#KP60 tidy up

Post by **Fred** » Wed Jul 20, 2016 10:22 pm

Thanks Jeff! I really appreciate that. After a long day car-hacking and then more long day firmware-hacking, it's just such a drag to do that. Awesome of you to help out! :-)

Fred wrote:So left to do are:

DONE! Sort out the bracket fastener situation

DONE! Tweak the bracket to give more clearance for drain bung and water pump bolt

DONE! Fix one radiator mount bracket

DONE! Derust and paint a few items

DONE! Pull the radiator support out of the car

DONE! Scuff up the pump mounting face until bright steel

DONE! Clean various fasteners that are greasy and/or rusty

DONE! Install the new water pump with a small amount of well placed silicone

DONE! Reinstall pulley, trigger wheel, bracket, sensor, bolts

Clean the rad support up, paint, reinstall

Scrub rusty water stains from fan shroud

Get the alternator fixed ASAP

Reinstall alternator and belt, tension belt correctly

Refill with water for the first time, bring up to temperature, check for pressure and leaks

Drain water, refill with glycol coolant at 35% and water 65%

As discussed, I plan to do more front end work before it all goes fully back together, but things are getting closer to sane again. More will occur today.

Related: I have no idea what's up with the alternator. I will find my blacktop one and see if it could be temporarily adapted to the 4K, and if not, put the 4K one back together how it was (with just a c clean) and suffer the noise it makes. Que sera sera.

Post by **Fred** » Fri Jul 22, 2016 12:25 pm

Only did light work on the KP today.

#KP60 radiator brackets soaking in #acid. I need a #chemistry lesson on why the white dust precipitates out. #Oxalic

Clean, but with instant surface rust. #KP60

Rust treatment applied and nearly dry. #KP60

Same water based rust treatment on the alternator bracket #KP60

Other side of radiator brackets with rubbers and grill present. #KP60

Zinc primer applied to the radiator and alternator brackets. #KP60

And, last but not least: A '94 Nissan Navara alternator that's destined to live on the #4K in my #KP60 because the stock one is unhealthy :-(

Just a few brackets and a connector away from a 10 fold increase in charging and an internal regulator :-D

DIYEFI.org Forum

Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!

Re: Fred's 1983 KP60 Toyota Starlet, take 2!